Random Orbital Sander
- 1 Plywood , 1/4" Thick , Full Sheet
- 1 Plywood , 1/2" Thick , Quarter Sheet
- 1 Board , 1x12 , 72"
- 3 Board , 1x6 , 72"
Hardware & Supplies
- 3 Tiles 12 3/4" X 12 3/4"
- 16 Kreg 1 1/4" coarse pocket screws
- 1 Titebond I wood glue
- 6 Sandpaper 100 - 220 grit
- 1 Liquid Nails Clear Silicone Adhesive
- 1 Minwax Satin Espresso Polyshades 1 step finish
- 45 5/8" pin nails
Please be sure to read through complete instructions before you begin any work on this project. It is also a good idea to dry fit the components before adding glue and doing final assembly. I built this headboard from 3/4" poplar and the least expensive 1/4" & 1/2" plywood I could find as I was using a polyurethane with ebony stain. So the type of wood was going to be hidden. You can build it from any wood you like and stain or paint it to your taste.
Cut out 3/4" pieces
Using the dimensions in the parts list cut the two stiles and the top and bottom rails from the 3/4" boards. The 52 inch height of the stiles can be adjusted depending on the height of your mattress. Optionally you can use a 3/16" router beading bit (I use a Freud 80-104) in your router table to add a beading detail to the inside edges of the rails and stiles that will outline the center tile area.
Add pocket holes and assemble frame
Using a Kreg pocket screw jig (set to 3/4" for all pockets on this project), drill pocket holes in the back of both ends of the top and bottom rails as shown in the attached diagram. It is a good idea to mark where you are putting the holes to prevent mistakes. Then assemble using Titebond I wood glue and Kreg 1 1/4" pocket screws. After assembly use 100 - 180 grit sandpaper to smooth all surfaces.
Cut 1/4" plywood and attach.
Using the dimensions listed in the parts list cut the 1/4" plywood back. Using Titebond I wood glue and 5/8" pin nails attach the back as shown in the following diagram.
Cut 1/2" plywood triangles
Using the following diagram cut the 4 small and 4 large triangles from the 1/2" plywood. Please note that the listed size of 12 3/4" is slightly large. The resulting dimension will actually be about 12.727" if cut correctly. Pythagoreans theorem A²+B²=C², 9²+ 9²=C², 81+81+C², 162=C², C=√162, C=12.727. Using 100 - 180 grit sandpaper smooth the plywood.
Add the Triangles to the headboard
Add the Triangles to the headboard as shown in the attached diagram. Attach using Titebond I wood glue and 5/8" pin nails (from the back side).
Prepare and add the tiles
Carefully measure the tile openings in the front of the headboard. Using a tile cutter or tile saw cut the three tiles to the proper dimensions. Using Liquid Nails Clear Silicone Adhesive attach the tiles to the front of the headboard.
Now that the build is complete use 220 sandpaper to do a once over on all surfaces in preparation for the finish. Clean well to remove all dust. (I use compressed air and clean dry rags). I used Minwax Satin Espresso Polyshades 1 step finish as my wife wanted a dark finish on the furniture for the guest bedroom.